PEM eConnect® Busbar Connector System

As eMobility and the shift to electric vehicles and renewable energy grow in scale, the demand for reliable, low-resistance, high-strength busbar connections has never been greater.

The current default solution includes the direct plating of busbars with silver or tin, and the use of additional loose hardware to join busbars. It’s a costly series of processes that often require busbars to be shipped to multiple vendors at multiple locations before they can be completed.

Enter the new PEM eConnect® Busbar Connector System – a streamlined, cost-saving, high-performance solution for joining busbars in electric vehicles, automotiveelectronics, and industrial applications.

Whether you’re facing challenges like high resistance, manufacturing inefficiencies, or costly materials, the PEM eConnect® system can revolutionize how your team connects, powers, and innovates.

Eliminate costly processing steps without sacrificing performance

Your challenge: Create busbar connections that maintain both electrical performance and mechanical integrity under extreme conditions.

Your solution: The PEM eConnect® Busbar Connector System.

Whether you’re facing challenges like high resistance, manufacturing inefficiencies, or costly materials, the PEM eConnect® system can revolutionize how your team connects, powers, and innovates.

The System At-A-Glance

This new fastening solution is two-piece setup designed to be installed in one step with a single pressing operation and consists of the PEM eConnect® Contact Bushing paired with our new mechanical fasteners – the ECKN™ PEM eConnect® Nut and the ECKS™ PEM eConnect® Stud.

The contact bushing is crafted from high-conductivity copper and plated with silver or tin, for lowelectrical resistance. Meanwhile, the mechanically installed fasteners introduce exceptionalstrength and durability to the design. Together, these components work seamlessly to provide superior mechanical and electrical performance.

With its simple one-step installation, the system eliminates the need for additional processes like busbar plating or complex cleaning routines. By making EV assembly processes quicker and more reliable, the eConnect Busbar Connector System is built for efficiency.

K81 Copper Contact Bushing
- Engineered for exceptional conductivity while featuring a hardness optimized for seamless installation into copper or aoluminum busbars.
Heat-Treated Steel Mechanical Fasteners
- Enhanced durability with strong, load-bearing threads and zinc plating to withstand the high demands of modern EV applications.

One-Step Installation Process
- A single pressing operation combines the fasteners and contact bushing for a simpler assembly process.
No Additional Preparation Required
- Eliminate expensive plating or labor-intesive cleaning steps. The system's knurled contact features clean oxidation layers automatically during installation for an optimal connection.

Patent-Pending Knurl Geometry
- The contact bushing's curved knurl breaks through aluminum and copper oxide layers to ensure consistent surface connections. This design maximizes contact area while maintaining a minimal footprint.
Adaptable to Thickness
- Customizable - solutions are tailored to specific panel thicknesses but can be easily adjusted for different sizes or use cases.

High push-out and torque-out resistance
Strong clamp force maintains consistent electrical connection over time

Exceeds resistance benchmarks, delivering less than 10 micro-ohms in 1000+ cycles, even under stress from humidity, temperature fluctuations, and thermal shock.

Ultra-Low Resistance, Superior Mechanical Strength

Less than 10 micro-ohms even after 1,000+ cycles
Maintains performance through humidity, temperature fluctuations, thermal shock
Copper alloy contact bushing with optimized hardness for exceptional conductivity
Push-out testing: 649N/146 in. lbs. (ECKN™ Nut) and 686N/154 in. lbs. (ECKS™ Stud)*
Torque-out testing: 14 Nm/124 in. lbs. for both components*
Heat-treated steel mechanical fasteners with strong, load-bearing threads

Eliminate Costly Processing and Supply Chain Complexity

No silver or tin plating required
Reduce third-party processing costs
Save on materials and complex cleaning routines
Fewer vendors needed for production
Reduce shipping between multiple locations
Less specialized labor

One-Step Installation, No Plating Required

Single pressing operation combines fasteners and contact bushing
Eliminates need for separate plating processes
No additional preparation or cleaning steps needed
Knurled contact features automatically clean oxidation layers during installation
Eliminates shipping to multiple vendors for plating services
Reduces supply chain complexity and production delays

*Performance values reported are averages when all proper installation parameters and procedures are followed. Variations in mounting hole size, sheet material, and installation procedure may affect performance. Performance testing this product in your application is recommended. We will be happy to provide technical assistance and/or samples for this purpose

Backed by Rigorous Testing

The PEM eConnect® system has gone through extensive mechanical and electrical reliabilitytesting to ensure it outperforms competing solutions and meets the critical standards of EVapplications.

Push-Out Testing achieved values of 649N/146 in. lbs. for the ECKN™ Nut and686N/154 in. lbs. for the ECKS™ Stud
Torque-Out Testing achieved values of 14 Nm/124 in. lbs. for ECKN™ Nut and14Nm/124 in. lbs. for the ECKS™ Stud
Thermal Shock and Humidity Cycling Testing passed with no sign of degradationacross extreme temperatures (-40°C to 125°C) and environments
Electrical Resistance Testing confirmed ultra-low resistance even after 1000+ cycles

Application Versatility

The PEM eConnect® system is designed for countless applications – adaptable to differentsizes, panel thicknesses, and use cases.

Easily join busbars to printed circuit boards in EV Charging systems
Create reliable busbar-to-cable connections in EV Powertrain components
Create reliable busbar-to-busbar connections for EV Power Distribution, Grid PowerStorage applications, and Industrial Switchgear solutions